1987 Honda Fourtrax 250 Plastics: A Restoration Guide

Hey guys! If you're anything like me, you have a soft spot for the classics, and the 1987 Honda Fourtrax 250 is definitely one of them. But let's face it, after years of adventures, those original plastics can start looking a little worse for wear. Scratches, cracks, and fading can really detract from the overall look of your trusty ATV. That's why I decided to put together this guide to help you restore or replace the plastics on your 1987 Honda Fourtrax 250. Whether you're aiming for a full restoration or just want to freshen things up, this article will walk you through the process.

Why Restore or Replace Your Fourtrax 250 Plastics?

Before we dive into the how-to, let's talk about why you might want to tackle this project in the first place. Restoring or replacing your Fourtrax 250 plastics isn't just about aesthetics, although that's certainly a big part of it. Here's a breakdown of the benefits:

Improved Appearance: Let's be honest, a shiny, new-looking set of plastics can make your old Fourtrax look like it just rolled off the showroom floor. This can be a huge source of pride and make your ATV stand out from the crowd.
Increased Resale Value: If you're thinking about selling your Fourtrax 250 down the road, restoring the plastics can significantly increase its value. Potential buyers are more likely to be interested in a machine that looks well-maintained.
Protection: While plastics are primarily cosmetic, they also offer some protection to the underlying components of your ATV. Cracked or broken plastics can expose these parts to the elements, leading to further damage.
Personalization: Replacing your plastics gives you the opportunity to customize your Fourtrax 250 and make it your own. You can choose from a variety of colors and styles to create a unique look that reflects your personality.

Assessing the Condition of Your Plastics

Okay, so you're convinced that restoring or replacing your plastics is a worthwhile project. The first step is to take a good, hard look at what you're working with. Assess the extent of the damage and determine whether restoration is possible or if replacement is the better option. Here are some things to consider:

Cracks: Small cracks can often be repaired, but large or numerous cracks may indicate that the plastic is too brittle to salvage.
Scratches: Scratches are inevitable, but deep scratches can be difficult to remove completely. Consider how much time and effort you're willing to invest in sanding and polishing.
Fading: Over time, exposure to the sun can cause the plastics to fade and become discolored. While some fading can be reversed with polishing, severe fading may require painting or replacement.
Missing Pieces: If you're missing chunks of plastic, replacement is likely the only option.
Overall Condition: Take into account the overall condition of the plastics. If they're extremely brittle or warped, it may be best to start fresh with a new set.

Once you've assessed the condition of your plastics, you can decide whether to attempt a restoration or opt for a replacement. If the damage is relatively minor, restoration can be a cost-effective way to bring your plastics back to life. However, if the damage is severe, replacement may be the better long-term solution.

Finding Replacement Plastics

If you've decided that replacing your plastics is the way to go, you have a few options to choose from. You can purchase new aftermarket plastics, search for used OEM (Original Equipment Manufacturer) plastics, or even try to find a complete used set from a parts bike. Here's a closer look at each option:

New Aftermarket Plastics: New aftermarket plastics are readily available from a variety of online retailers and ATV parts suppliers. These plastics are typically made from durable materials and are designed to fit your 1987 Honda Fourtrax 250 perfectly. They also come in a variety of colors and styles, allowing you to customize the look of your ATV. While aftermarket plastics may not be exactly the same as the original OEM plastics, they are often a more affordable option.
Used OEM Plastics: If you're looking for the most authentic restoration possible, you may want to consider searching for used OEM plastics. These plastics are the original parts that came with your Fourtrax 250, so they will fit perfectly and maintain the original look of your ATV. However, used OEM plastics can be difficult to find and may be more expensive than aftermarket plastics. You can search for used OEM plastics on online marketplaces, ATV forums, and local salvage yards.
Complete Used Set from a Parts Bike: Another option is to find a complete used set of plastics from a parts bike. This can be a good way to get a matching set of plastics at a reasonable price. You can often find parts bikes for sale on online marketplaces and ATV forums. Just make sure to inspect the plastics carefully before you buy them to ensure that they are in good condition.

When searching for replacement plastics, be sure to check the compatibility with your specific year and model of Fourtrax 250. The 1987 model may have slightly different plastics than other years, so it's important to ensure that you're getting the correct parts.

Restoring Your Existing Plastics

If your plastics are in decent shape overall, you might be able to restore them instead of replacing them. This can save you money and preserve the original look of your Fourtrax. Here's a step-by-step guide to restoring your ATV plastics:

Clean the Plastics: Start by thoroughly cleaning the plastics with soap and water. Use a mild detergent and a soft brush to remove any dirt, grime, or grease. Rinse the plastics well and allow them to dry completely.
Sand the Plastics: Once the plastics are clean and dry, you can begin sanding them to remove scratches and imperfections. Start with a coarse-grit sandpaper (e.g., 400-grit) and gradually work your way up to a finer-grit sandpaper (e.g., 800-grit, 1000-grit). Be sure to sand in a circular motion and apply even pressure. If you have deep scratches, you may need to start with an even coarser grit sandpaper.
Polish the Plastics: After sanding, you'll need to polish the plastics to restore their shine. Use a plastic polish and a soft cloth or polishing pad to buff the plastics. Apply the polish in a circular motion and buff until the plastics are smooth and glossy. You may need to repeat this step several times to achieve the desired results.
Apply a UV Protectant: To protect your restored plastics from fading and discoloration, apply a UV protectant. This will help to keep your plastics looking their best for years to come. There are many different UV protectants available, so choose one that is specifically designed for use on plastics.
Repair Cracks (Optional): If your plastics have any cracks, you can repair them using a plastic repair kit. These kits typically include a special adhesive and a reinforcing mesh that you can use to patch the cracks. Follow the instructions that come with the kit carefully to ensure a proper repair.

Painting Your Plastics

If your plastics are severely faded or discolored, you may want to consider painting them. This can be a great way to give your Fourtrax 250 a fresh new look. However, it's important to use the right type of paint and follow the proper procedures to ensure a durable and long-lasting finish. Here's a basic guide to painting your ATV plastics:

Prepare the Plastics: Start by cleaning and sanding the plastics as described above. Be sure to remove any loose paint or rust before sanding. You may also want to apply a plastic adhesion promoter to help the paint stick to the plastics.
Prime the Plastics: Apply a coat of plastic primer to the plastics. This will help the paint adhere to the plastics and provide a smooth, even surface for the paint to bond to. Allow the primer to dry completely before proceeding.
Paint the Plastics: Apply several thin coats of paint to the plastics, allowing each coat to dry completely before applying the next. Use a high-quality automotive paint that is designed for use on plastics. You can choose any color you like, but be sure to select a color that is compatible with your Fourtrax 250.
Clear Coat the Plastics (Optional): For added protection and shine, you can apply a clear coat to the plastics after painting. This will help to protect the paint from scratches and fading. Allow the clear coat to dry completely before handling the plastics.

Reinstalling the Plastics

Once you've restored or replaced your plastics, it's time to reinstall them on your Fourtrax 250. This is a relatively straightforward process, but it's important to take your time and make sure that everything is properly aligned. Here are a few tips for reinstalling your plastics:

Refer to a Service Manual: If you're not sure how to reinstall the plastics, refer to a service manual for your 1987 Honda Fourtrax 250. This will provide detailed instructions and diagrams to help you through the process.
Start with the Larger Pieces: Begin by installing the larger pieces of plastic, such as the fenders and side panels. These pieces will typically have several mounting points, so be sure to align them properly before tightening the bolts.
Work Your Way to the Smaller Pieces: Once the larger pieces are in place, you can start installing the smaller pieces, such as the headlight surround and the taillight housing.
Tighten the Bolts Carefully: When tightening the bolts, be careful not to overtighten them. Overtightening can damage the plastics or strip the threads in the mounting holes. Use a torque wrench to ensure that the bolts are tightened to the proper specifications.

Enjoy Your Restored Fourtrax 250!

Congratulations! You've successfully restored or replaced the plastics on your 1987 Honda Fourtrax 250. Now it's time to step back and admire your work. Your trusty ATV should look like new again, ready for many more adventures. Remember to take care of your plastics by cleaning them regularly and applying a UV protectant to keep them looking their best. Happy riding!